Glow-worm 100sxi, Installation And Servicing Manual

Page 1: ...Supplied By www heating spares co Tel 0161 620 6677 www glow worm co uk Installation and Servicing High Efficiency System Store Ultrapower sxi G C No 41 019 10 G C No 41 019 09 170sxi 100sxi 13121 ...

Page 2: ...nt voltages lightning strikes or any act of vandalism or misuse 2 The proof of purchase must be produced in the event of any warranty claim bill of sale 3 The appliance must be installed by a competent person approved at the time by the Health and Safety Executive to the prevailing standards installation book and building regulations at the time of installation 4 The Benchmark Installation Commiss...

Page 3: ... Gas Water Boiler Connection 8 20 Condensate Safety Discharge Valve Connections 9 22 Flue Preparation and Installation 10 23 Electrical Connection 11 37 Commissioning 12 40 Servicing 13 44 Fault Finding 14 49 Replacement of Parts 15 56 Spare Parts 16 69 Declaration of Conformity 17 71 INTRODUCTION INSTALLATION MAINTENANCE These instructions consist of Installation Servicing Fault Finding Replaceme...

Page 4: ...ectrical Supply The electrical installation must be installed by a competent person approved at the time by the Health and Safety Executive and in accordance with the relevant standards The boiler and immersion heater must be earthed All system components shall be of an approved type and all wiring to current I E E wiring regulations External wiring must be correctly earthed polarised and in accor...

Page 5: ...d The Gas Safety Installation and Use Regulations The appropriate Buildings Regulations either The Building Regulations The Building Regulations Scotland The Building Regulations Northern Ireland The Water Supply water fittings Regulations 1999 and water byelaws 2000 Scotland Statutory Requirements The Health and Safety at Work Act Control of Substances Hazardous to Health COSHH The Current I E E ...

Page 6: ...the temperature drops to 5O C The burner will switch off when the temperature reaches 35O C Frost protection is also built into the cylinder Should the cylinder temperature fall below 10O C the tank is re heated to a temperature of 15O C The cylinder has a built in disinfection cycle which raises the water temperature to 70O C for 1 hour every Wednesday at 2 00am Condensate Drain Blockage As a saf...

Page 7: ... Tel 0161 620 6677 7 1 Boiler Specifications Data All dimensions are given in millimetres except as noted See diagram 1 1 and the Boiler Specification Table below 13340 The data label is positioned inside the boiler module on the base ...

Page 8: ...Supplied By www heating spares co Tel 0161 620 6677 8 1 Boiler Specifications 13247 Diagram 1 1 ...

Page 9: ...Supplied By www heating spares co Tel 0161 620 6677 9 Diagram 1 2 13290 1 Boiler Specifications ...

Page 10: ...rational and servicing clearances are provided see diagram 2 1 Additional clearances may be beneficial around the boiler for installation and servicing For flue installations where external access is not practicable consideration should be given for the space required to insert the flue internally which may necessitate a clearance larger than those specified in diagram 2 1 2 3 Timber Frame Buildin...

Page 11: ... a condensing boiler some pluming may occur from the flue outlet This should be taken into consideration when selecting the position for the terminal NOTE If necessary it is permitted to increase the terminal protrusion through the outside wall to greater than the minimum dimension of 87mm but no more than 600mm Carports or similar extensions of a roof only or a roof and one wall require special c...

Page 12: ...e page 34 Twin Flue Adapter concentric flue Ø80 Part No A2011000 Plume Management Kit page 37 Basic set concentric flue Ø60 100 White Part No A2044100 Black Part No A2044000 for use with Part No A2043400 and Part No A2043600 Vertical Flue page 31 Vertical Flue Adapter concentric flue Ø60 100 Part No A2024600 Vertical flue terminal kit concentric flue Ø60 100 Part No 2000460480 14845 Ridge Tile Ter...

Page 13: ...am 4 2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump see section 12 Commissioning 4 5 Filling the Sealed System NOTE The water pressure at the boiler must be at least 0 7bar to enable filling the boiler to a minimum pressure through the integral filling device see diagrams 4 1 and 12 2 4 6 Water Treatment In the case of an ex...

Page 14: ...et pressure however for optimum performance it is recommended that 22mm feed pipe is used with an inlet pressure at the appliance of 2 bar NOTE Higher pressure can be tolerated as the boiler is fitted with a pressure reducing valve set at 3 5 bar 5 2 Expansion Vessel The boiler has an integral expansion vessel with a capacity of 12 litres 2 6 gallons with a charge pressure of 3 bar NOTE The expans...

Page 15: ...tundish should be vertical located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e g the temperature relief valve NOTE The tundishes are factory fitted during manufacture The discharge pipe D2 from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge pref...

Page 16: ...able 1 Sizing of copper discharge pipe D2 Control and safety valves MUST NOT be tampered with The discharge pipe MUST NOT be blocked or used for any other purpose The tundish is factory fitted and MUST NOT be removed 13449 Discharge pipe D2 from tundish Resistance created by each elbow or bend Maximum resistance allowed expressed as a length of straight pipe i e no elbow or bends Discharge pipe D1...

Page 17: ...FROM APPLIANCE EXTERNAL LENGTH OF PIPE 3M MAX 25mm MIN SEAL BOTTOM OF TUBE SEALED DIA 100mm PLASTIC TUBE 300mm MIN GROUND either or 500mm MIN HOLE DEPTH 400mm MIN LIMESTONE CHIPPINGS 2 ROWS OF 3 x 12mm HOLES AT 25mm CENTRES 50mm FROM BOTTOM OF TUBE HOLES TO FACE AWAY FROM HOUSE External Soil and Vent Pipe or Rainwater Pipe Internal Soil and Vent Pipe External Termination into Soakaway Internal Ter...

Page 18: ... blue 4 OFF M Cartridge Screws stored in cartridge 2 OFF L Electrical Cartridge 1 OFF K Floor Template 1 OFF J Pump Washer 1 OFF H 3 4 Sealing Washer beige 5 OFF G 1 2 Sealing Washer 2 OFF F 3 4 Sealing Washer white plastic 4 OFF E 15mm Copper Tail 1 OFF D 22mm Copper Tails 4 OFF C Condensate Connection Pipe 1 OFF B User Instructions not illustrated 1 OFF A Installation booklet not illustrated 1 O...

Page 19: ... extending the dashed inclined line on the template to the side wall This dashed line is drawn at 44mm metre 2 5 rise from the boiler Where this line reaches the side wall a horizontal line should be marked The vertical centre line of the flue should then be marked on the back wall To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal ...

Page 20: ...in accordance with the current issue of BS6891 and in IE the current edition of I S 813 Domestic Gas Installations Remove the manometer and secure the test point screw On completion of system connections and as an aid to installation slacken the jig securing screws this will allow a greater tolerance of site conditions when connecting the isolation valves to the boiler Diagram 8 1 13402 IMPORTANT ...

Page 21: ...LE Diagram 8 2 8 Gas Water Boiler Connection 8 3 Boiler Module Connection Unpack the boiler module from its carton Position the boiler on top of the tank ensuring the correct engagement of the locating pins see diagram 8 3 Remove the front panel securing screws and lift the panel off at the top locating bracket see diagram 8 2 Position the plastic sealing washers as shown in diagram 8 3 and secure...

Page 22: ...LEXIBLE CONDENSATE HOSE FLEXIBLE CONDENSATE CONNECTION PIPE 13312 Diagram 9 2 Diagram 9 3 13458 FLEXIBLE CONDENSATE HOSE FLEXIBLE CONDENSATE HOSE CONNECTION TO BOILER MODULE 9 Condensate Safety Discharge Valve Connections 9 1 Safety Discharge Valve The pipes must be extended using not less than 22mm o d pipe to discharge in a visible position outside the building facing downwards preferably over a...

Page 23: ...m metre to allow condensate to run back into the boiler and out via the condense trap siphonic drain The flue can be installed from inside the building when access to the outside wall face is not practicable The diagrams below describe the lengths achievable without the use of extensions or elbows Horizontal Telescopic Flue Diagram 10 1 13337 L FLUE C Max flue length 668mm 181 394 5mm min clearanc...

Page 24: ...LY SEALING COLLAR TRIM RING SECURING COLLAR FLUE ELBOW GASKET fitted SEALING TAPE telescopic only A2043600 Top Outlet Horizontal telescopic flue pack SCREW x 1 SCREW x 2 SCREW x 2 SCREW x 4 13221 Diagram 10 3 15418 10 Telescopic Flue Length Preparation and Installation Diagram 10 2 ...

Page 25: ...s less than 320mm DO NOT cut the flue it can project to a maximum of 600mm if this is not desirable then a Standard flue MUST be used and cut to length 10 4 SIDE Flue With the flue elbow temporarily fitted measure the distance from the outside wall to the butt joint see diagram 9 6 If the measurement Y exceeds LH 204mm RH 417mm then the appropriate length of extension pipe is required If the dimen...

Page 26: ...e joint see diagram 10 7 Fit the sealing collar onto the locating ring on the flue terminal see diagram 10 8 With the flue elbow removed push the flue assembly into the wall externally or internally until the end of the assembly protrudes a short way from the inside face of the wall This will enable the internal trim ring if required to be positioned and allow the flue assembly to be drawn back up...

Page 27: ...to have a continuous fall to the boiler of at least 2 5o 44mm metre to allow condensate to run back into the boiler and out via the condense trap siphonic drain The flue can be installed from inside the building when access to the outside wall face is not practicable The diagrams below describe the lengths achievable without the use of extensions or elbows 10 Standard Flue Length Preparation and I...

Page 28: ...Supplied By www heating spares co Tel 0161 620 6677 28 Diagram 10 12 12841 Diagram 10 13 15418 10 Standard Flue Length Preparation and Installation ...

Page 29: ...ore completion Long lengths of flues must be secured to the walls or ceilings they run against Use at least one fixing bracket for every flue extension that is used After cutting inner flue tubes ensure that you de burr and chamfer the male tube end to prevent damage Inspect the flue pipes before fitting and do not install damaged or dented flue components When assembling the flue system ensure th...

Page 30: ...plied Draw the flue assembly from wall and engage the flue duct into the elbow and butt fit between the air duct and flue elbow Fit the securing collar into position Ensuring correct alignment of the flue mark through two of the pre drilled holes in the securing collar Remove securing collar and drill two 3mm diameter holes one in the elbow and one in the air duct take care not to pierce the inner...

Page 31: ...straight flue length is 12 metres plus the terminal for each 87 5o or 2x45o bends fitted the maximum length must be reduced by 1 metre see diagram 10 19 10 NOTE 2x45º bends can replace 1x87 5º bend if necessary When using 87 5º bends any horizontal extension pipe should be inclined by a minimum of 44mm metre 2 5 towards the boiler to facilitate condense removal see a in diagram 10 19 Alternatively...

Page 32: ...ecure the first extension pipe to the flue adapter with the securing collar supplied by positioning the collar centrally over the joint then tighten the two screws on the securing collar see diagram 10 23 Fit more extension pipes as required using the collar and screws supplied with each extension pipe To fit position the collar centrally over the joint tighten the two screws on the securing colla...

Page 33: ...ard the plain end of the tube The cuts must be square and made free of burrs to allow correct assembly NOTE The flue pipe is 10mm longer than the air pipe see diagram 10 25 Diagram 10 25 12983 13317 Diagram 10 23 Carefully push the terminal assembly upwards to allow room for fitting the final flue piece Fit a fixing bracket to the terminal assembly Pull the terminal assembly down and join to the f...

Page 34: ... Tel 0161 620 6677 34 10 Twin Flue Length Preparation and Installation Diagram 10 26 15407 WALL SEAL WALL SEAL Secure long flue lengths to walls or ceiling at every joint or on straight flue runs at every joint and every metre flue run ...

Page 35: ...twin flue system installation are shown in diagram 10 27 Boiler Connection IMPORTANT The flue seals are sensitive to mineral oil based lubricants Do not grease the seals If the seals do need to be lubricated use only water Push the twin flue adaptor onto the outlet of the boiler with the air inlet to the left hand side Secure the adaptor to the top panel with the screws provided Care should be tak...

Page 36: ...ing seal making square and free from burrs Push the horizontal terminal through the wall to engage the final pipe piece and pull back ensuring the grey wall seals are fully pulled up to the outside and inside wall faces Vertical Pipes Completion of Installation Refer to diagram 10 26 For installation of a attach the twin pipe to concentric flue adaptor part number A2011600 to the base of vertical ...

Page 37: ...ee All system components must be of an approved type Electrical components have been tested to meet the equivalent requirements of the BEAB Do not interrupt the mains supply with a time switch or programmer Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator Isolation should preferably be by a double pole switched fus...

Page 38: ...loose in the electrical cartridge these will be required to secure the cartridge into the electrical interface housing Slacken the two screws of the cable strain relief in the electrical cartridge see diagram 11 2 Route the mains supply and systems cables through the strain relief and connect to the relevant plug dependant upon your choice of system controls refer to relevant sections 11 2 and 11 ...

Page 39: ...l automatically be disabled 11 4 Disabling the internal CH Programmer If fitting an external proprietary CH Programmer it is necessary to disable the Internal Programmer a Press and hold the mode button for 5 seconds The display will change to flashing 0 b Use the or button to scroll to 96 c Press MODE to confirm d The display now shows a flashing d 0 Use the or key to scroll to d 92 e Press MODE ...

Page 40: ...iler to the domestic water tank and to the hot water taps Starting at the lowest tap turn the hot taps off one at a time until the hot water pipework is purged of air Carefully slacken but DO NOT remove the air vent screw on the domestic pump to release any trapped air within the boiler see diagram 12 2 secure when procedure completed NOTE The water pressure at the vent point is that of the incomi...

Page 41: ...ls are displayed The hot water tank has priority over central heating The appliance will enter a self checking routine then the ignition sequence will commence The digital display will show the tank temperature setting in hot water mode If the burner fails to light the fan will stop Initially this may be due to air in the gas supply line The boiler will automatically have five attempts at ignition...

Page 42: ...e filling taps 3 Vent all air from the system repeat step 2 as necessary until the system is full and all the air has been removed 4 IMPORTANT To comply with the water regulations the flexible hose must be disconnected from the double check inlet valve undo the nut and pull the flexible hose from the valve 12 6 Gas Inlet Pressure and Gas Rate The supply from the governed meter must be of adequate ...

Page 43: ... freezing Note Sealed System Contact your installation servicing company as draining refilling and pressurising MUST be carried out by a competent person approved at the time by the Health and Safety Executive Leave these instructions and the Benchmark Installation Commissioning and Service Record with the user 12 11 LPG CONVERSION Do Not operate the boiler without water During the conversion to P...

Page 44: ...s checked and serviced at regular intervals The frequency of servicing will depend upon the particular installation and usage but in general once a year should be enough 2 It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety Executive 3 Before commencing with a service or replacement of parts the boiler should be isolated from the elec...

Page 45: ...necessary to complete a full service of the appliance and then repeat the combustion check procedure If after servicing and adjustment of the appliance the combustion values are still unacceptable and after further remedial work has been carried out the appliance must be disconnected until the CO CO2 ratio is acceptable Advice can be sought from the Glow worm Technical Helpline 13 1 Servicing NOTE...

Page 46: ...SPARK GAP 4mm SECURING SCREW 2 OFF EARTH LEAD 13273 Diagram 13 8 Diagram 13 7 Diagram 13 5 Diagram 13 6 13 3 Spark Electrode NOTE If the functional checks did not indicate poor combustion then it is not necessary to service this component Disconnect the spark electrode plug and earth lead Remove the two securing screws and withdraw the spark electrode carefully from the combustion chamber see diag...

Page 47: ...rmostat see diagram 13 11 Remove the four burner door nyloc nuts one of these also holds the silencer bracket see diagram 13 11 Gently remove the fan gas valve and burner assembly from the combustion chamber taking care not to trap the primary return thermistor electrical cables Clean the burner with a soft brush taking great care not to damage the front insulation DO NOT use wire or sharp instrum...

Page 48: ...VALVE AND FAN BURNER DOOR Diagram 13 12 Diagram 13 13 15452 GAS CONTROL VALVE OFFSET ADJUSTMENT THROTTLE ADJUSTER Diagram 13 15 13762 SEAL 4 pieces BOILER MODULE FRONT CASING PANEL FLEXIBLE CONDENSATE HOSE CONDENSE TRAP SIPHONIC DRAIN Turn anti clockwise to remove SERVICE FILL LEVEL Diagram 13 14 13326 13 7 Boiler Module Front Casing Panel Seal Check Check the condition of the seal if worn or dama...

Page 49: ... fill and vent the system as described in section 12 3 Check that all external controls are on Check the functional flow diagram 14 3 13845 14 2 Fault Memory The Fault memory stores details of the ten most recent faults To access this menu a Press and hold MODE for 5 seconds b When the display shows a flashing 0 press MODE button c Press a button to scroll back through the fault memory Position 1 ...

Page 50: ...ding 13119 Diagram 14 2 g br BROWN b BLUE g y GREEN YELLOW g GREEN gy GREY bk BLACK y YELLOW pk PINK p PURPLE or ORANGE w WHITE r RED KEY or b r w bk g y b br w b r bk r w bk br g y b b r g y g y g y b br g y b b gy w r b w y b bk bk bk bk r bk g w or p br g y b br g y ...

Page 51: ...es the display flash F during or after a DHW demand Consult the Fault Table Is there anything displayed Is the display flashing F Initiate a DHW demand Adjust DHW setpoint to 620C and turn on a hot water tap Does the boiler light No No Yes Yes Yes Yes Yes No No No Yes START Yes No No Consult the State List 13012 CENTRAL HEATING DHW 13411 14 Fault Finding Diagram 14 3 ...

Page 52: ...Supplied By www heating spares co Tel 0161 620 6677 52 14 Fault Finding 13412 Diagram 14 4 Fault Codes ...

Page 53: ...Supplied By www heating spares co Tel 0161 620 6677 53 14 Fault Finding 13447 Diagram 14 4a Fault Codes continued ...

Page 54: ...pressure in bar d 28 Option Relay 2 Reserved for future use d 27 Option Relay 1 Reserved for future use d 91 Internal Programmer type 0 24 hour 1 7 day default d 92 Enable Disable Internal Programmer 0 CH Off DHW Off 1 CH Off DHW On 2 CH On DHW Off 3 CH On DHW On Default Domestic hot water flow temperature reading Tank setpoint Tank temperature Domestic hot water setpoint Heating temperature setpo...

Page 55: ...ze active fan speed variation too high Check fan connection waiting during blocking function S 34 frost protection active Priority 4 Temperature below 8O C check thermistor connection if this is not true S 36 No Heating demand from external controls 24V Check wiring in external controller Check wiring at Installer Interface S 42 Accesory Module is blocking burner operation Check accessory module S...

Page 56: ... to drain the boiler out through the filling loop hose After servicing or replacing parts open the heating flow and return isolating valves and refill vent and pressurise the heating circuit refer to section 12 3 Close the drain valve and disconnect the hose Check for leaks Draining of Boiler Domestic Water Circuit Drain the domestic water circuit by closing the cold water isolation valve see diag...

Page 57: ...rode carefully from the combustion chamber see diagram 15 3 Fit new gasket when replacing 15 7 Gas Valve For access refer to section 15 1 Remove the electrical plug from the gas valve see diagram 13 10 Refer to section 13 4 for removal of the fan gas valve and burner assembly Before removing the gas valve from the fan note its position and mark its orientation on the fan and gas valve bodies this ...

Page 58: ...ion 15 6 Remove burner as described in the appropriate section of 15 9 and withdraw the insulation see diagram 13 12 NOTE THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED 15 11 Rear Insulation For access refer to section 15 1 Refer to section 13 4 for removal of the fan gas valve and burner assembly Remove securing screw and washer in the centre of the insulation and withdraw insulation see diag...

Page 59: ...aces towards the front of the appliance 15 14 Heat Exchanger Refer to Manual Handling Operations 1992 For access refer to section 15 1 Drain the boiler heating circuit see section 15 1 Drain the boiler domestic water circuit see section 15 1 Disconnect the flue connection refer to section 10 Remove the silencer refer to section 13 2 Remove the igniter unit electrical connections refer to diagram 1...

Page 60: ... 11 13342 Remove the two connection clips securing the flow and return pipes to the heat exchanger see diagram 15 9 Move the pipes away from the heat exchanger Remove the four heat exchanger securing screws and clamps see diagram 15 8 CAUTION There will be water in the heat exchanger Remove the push fit condense pipe from the bottom of the heat exchanger see diagram 15 10 Carefully remove the heat...

Page 61: ...embly 15 Replacement of Parts 15 17 Domestic Pump For access refer to section 15 1 Drain the boiler domestic water circuit see section 15 1 Remove the domestic expansion vessel and place in its service position see diagram 13 6 Disconnect the electrical connection from the main PCB see diagram 15 13 Unscrew the union nut at the pump top connector to the DHW pipe Unscrew the pipe union nut from the...

Page 62: ...st of the controls 15 20 Heating Flow Thermistor For access refer to section 15 1 The primary flow thermistor is situated underneath the heat exchanger refer to diagram 15 16 Remove the electrical connections from the thermistor Remove the thermistor noting its position on the flow pipe NOTE When reconnecting the polarity of the wiring to thermistors is not important Diagram 15 14 13252 SAFETY DIS...

Page 63: ...on 15 1 Refer to section 15 1 to drain the boiler heating circuit Refer to section 15 1 and drain the boiler domestic water circuit Refer to diagram 15 20 Remove the four screws securing the plate to plate heat exchanger to the hydroblock There will still be water present so carefully pull the plate to plate heat exchanger upwards to remove When replacing the plate to plate heat exchanger ensure t...

Page 64: ...to the boiler chassis Rotate the gas pipe upwards and clear of the chassis panel Remove the 3 screws which retain the three way valve refer to section 15 16 Grip the LH and RH hydroblocks simultaneously and lift clear of the spigots on the mounting bracket The RH hydroblock should be drawn upwards past the plastic three way valve body NOTE Before removing the bypass tube from the hydroblocks take ...

Page 65: ... pressurise the boiler Adjust the bypass as described in commissioning see section 12 8 15 28 Pressure Reducing Valve For access refer to section 15 1 Refer to diagram 15 23 Slacken the three screws securing the pipe retaining bracket see diagram 8 3 Undo the union connection at the isolation valve and then the union nuts to remove the reduced pressure zone valve Fit new O rings 15 29 Safety Relie...

Page 66: ...the immersion heater a new gasket is also supplied 15 32 Condense Trap Siphonic Drain For access refer to section 15 1 Remove the flexible condensate hose by pulling out of condense trap and siphonic drain see diagram 13 14 Refer to diagram 15 26 Remove the securing screw holding the trap drain Remove the float to clean it When replacing ensure that the float is inserted correctly as shown in diag...

Page 67: ...x cover ensure the leads do not become trapped 15 35 Fuse Main PCB Control Box For access refer to section 15 33 The fuse is located at top left hand side of the main PCB see diagram 15 28 15 36 User Interface Refer to section 15 33 for access Remove the main PCB refer to section 15 34 Remove the electrical connection Gently ease back the retaining clips see diagram 15 29 Withdraw the board When r...

Page 68: ...er E88 867 5 0020014161 Automatic Air Vent H42 754 6 0020018812 Burner Door Seal Kit H49 385 7 0020020781 Flow Return Thermistor H42 792 8 0020014171 Central Heating Pump H42 760 9 0020014173 Safety Discharge Valve H42 758 11 0020037668 Main PCB H52 597 12 0020038183 Primary Expansion Vessel H52 505 13 0020038257 Domestic Expansion Vessel H52 591 14 0020038167 Temperature Pressure Relief Valve H52...

Page 69: ...Supplied By www heating spares co Tel 0161 620 6677 69 16 Spare Parts Diagram 16 1 11 1 2 3 4 7 6 23 8 9 22 21 19 20 14 18 13 12 16 17 15 5 24 13325 ...

Page 70: ...Supplied By www heating spares co Tel 0161 620 6677 70 17 Declaration of Conformity ...

Page 71: ...Supplied By www heating spares co Tel 0161 620 6677 71 Notes ...

Page 72: ...co Tel 0161 620 6677 www high efficiency info Because of our constant endeavour for improvement details may vary slightly from those shown in these instructions Glow worm Nottingham Road Belper Derbyshire DE56 1JT 0020048525 04 09 09 ...